Centrifuges

Centrifuges


Applications:
 Solids removal
 Barite recovery
 Chemical Enhanced Dewatering (CED)
Basic centrifuge components


Skid

Rotating Assembly
 Bowl
 Scroll (conveyor or screw)
 Gearbox

Drive motor

Over-torque protection

Feed pipe

Feed pump

Options
 Control packages
 Variable speed packages
Centrifuges


Do centrifuges separate by size or
weight?
 Remember Stokes Law
 Centrifuges separate by
Mass i.e. specific gravity x
volume
 Settling

Stokes Law
V= d• (SGS-SGL) • G
K•

V = Settling velocity
d = diameter of solid
SGS= Specific Gravity
Solid
SGL= Specific Gravity
Liquid
G = Gravitational force
K = Numeric Constant
 = Viscosity of liquid
Stokes Law

IF Settling Velocity

Particle diameter increases Increases

Specific gravity differential

Increases
increases

Gravitational force increases Increases

Viscosity increases Decreases

Theory of operation

Creates high G-force to promote faster settling time

Slurry is fed to rotating assembly, moving at speed
 Solids in slurry are thrown against the inside of bowl
 Solids (cake or discharge)are removed by the scroll
 Liquid (filtrate, centrate or effluent) flows out the other
end, liquid is discharged through epicentric ports
Basic centrifuge operation

Feed
Mud In

Effluent
Solids
RPM of Bowl

Example:

Size of Motor Pulley X RPM of Motor = RPM of Bowl

Size of R/A Pulley

Size of Motor Pulley = 250mm

Size of Rotating Assembly Pulley = 145mm

250 X 1750 = 3017 RPM

145
Calculating G-force

G-force = 0.0000142 x rpm2 x bowl diameter (inches)

HS3400 example:
 0.0000142 x28912 x 14 = 1662 Gs
• 1650 = 541 Gs
• 2000 = 795 Gs
• 2500 = 1242 Gs
• 3250 = 2099 Gs
Slurry in

Solids out Liquid out

Effects of G-Force

G-Force = .0000142 x rpm2 x bowl diameter (inches)


Increased G =
 Improved settling velocity
 Improved separation efficiency
 Improved effluent clarity
G-Force, Speed & Bowl Diameter
3000

2500

2000
G-Force

1500

1000

500

0
2000 2500 3000

14 795 1243 1789

3400
18 1022 1598 2300
1850
2172 21 1193 1864 2684
Speed (rpm )

G-Force = .0000142 x rpm2 x bowl diameter (inches)

Centrifuges
Design factors

Centrifuge size

Centrifuge speed

Scroll design

Pond depth

Gearbox type

Differential speed

Feed pump type and size

Control options
 Variable main drive, back-
drive & feed pump
 Electric or hydraulic
powered
Scroll design and pitch

Traditional designs use a closed hub and attached scroll

The scroll (which can also be called the conveyor or screw) can
vary by pitch and lead
 Pitch is the distance between flights
 Single lead scrolls have one set of flights
 Double lead scrolls have two sets flights
DIFFERENTIAL

A gear box is used to rotate the bowl and conveyor at
different speeds

The conveyor normally runs slower than the bowl

The differential is the difference in speed between the
bowl and the conveyor. Varying the speed of the pinion
shaft in the gear box with the conveyor drive motor
changes the differential.

On the HS3400 centrifuge the gearbox input shaft is held
stationary so the differential speed is fixed at the ratio of
the gearbox i.e. 52:1
Variable speed drive options

Control options: Electric or Hydraulic powered


Some models are available with variable speed options
that can include
 Hydraulically variable speed drive(s) or
 Electric inverter variable speed drive(s)

Variable speed main drive

Variable speed main and back drive

Variable speed pump
Electric vs. Hydraulic


Electric Variable Frequency Drive (VFD)
 Complete Control
 More Versatile

Full Hydraulic Variable Speed
 Self adjust itself based on torque feedback to PLC
 High Maintenance
Factors affecting performance and unit selection

Application factors
 Solids size and density
 Feed rate requirement
 Slurry properties
 Viscosity
 Density
 Temperature
 Power requirements


Objectives
 Low gravity solids removal
 High gravity solids recovery
 Clarification
 Chemical use (dewatering)
Torque Protection


Torque sensing capabilities to automatically throttle
back or shut down feed pumps

Torque sensing abilities to reduce scroll speed,
(increase differential and thus extract more solids)

Increase scroll speed to reduce torque

Resumes normal operation or shuts down
Torque Limit Switch

Protective devices
 VFD
 Spring loaded couplings, or
arms (shown)
 Trips the limit switch
 Limit switch is easily
reset
 Shear pins will break or
shear, causing the torque
arm to contact a limit switch.
 The shear pin must be
replaced
 Limit switch needs reset

In both cases the limit switch
kills the centrifuge and also the
feed pump (electrical
interconnection) HS-3400 torque control arm
with limit switch
Torque Protection

Torque is limiting factor on how
many solids are removed

Virtually all centrifuges will plug with
solids when pushed beyond their
limits

This may be due to the following
 Incorrect operation
 Excess feed rate
 Too small of a differential
speed..scroll out faster
 Slugging of the centrifuge with
solids…poor upstream
separation, poor feed pump or
control

Do not run the units at
100% capacity

Recommend feed rate;
 75 to 80% capacity
 Utilize Positive
Displacement Feed
Pumps
Pool or Pond Depth

Decanting centrifuges have the
ability to change pool or pond
depth

Change these as needed when
machine performance is
 Typically lower pond depths
produce dryer solids
 Deeper pond depths
produce cleaner effluent


This can be achieved with
 Replaceable dams,
provided in matched sets
Liquid vs. Solids Capacity

Capacity is measured in liquid and solid terms

 Bowl capacity is maximum liquid throughput before spillover into solids discharge ports

 Solids removal capacity is maximum tonnage before torque overload or plugged machine

 Variable speed pumps or throttling valves should be used to govern feed rates

 Good operation is a balancing act

Residence time, moisture, cut

Residence time: The length of time a particle is in the centrifuge.

 Shorter residence times increase moisture content and separate larger solids

 Longer residence times produce finer cuts, but may not necessarily yield drier discharge since
they remove smaller particles, which have more surface area

 Residence time is governed by feed rate

 Cuttings dryness is governed by differential speed.

HS 3400 Standard Size Ring Dams

Ring Dam Size

246 252 285

Depth of Pond

Dry Beach Length

Fluid Capacity
Pond Depth and Beach length

Ring Dam Size

246 252 285

Depth of Pond 52 mm
Dry Beach Length 35mm

Fluid Capacity
Comparison of pond depth and beach length

Ring Dam Size

246 252 285

Depth of Pond 55mm 52mm

Dry Beach Length 17mm 35mm

Fluid Capacity
Comparison of Pond Depth and Beach Length

Ring Dam Size

246 252 285

Depth of Pond 55mm 52mm 35mm

Dry Beach Length 17mm 35mm 130mm

Fluid Capacity
Liquid Capacity

Ring Dam Size

246 252 285

Depth of Pond 52 mm
Dry Beach Length 35mm

Fluid Capacity 54 litre

Liquid Capacity

Ring Dam Size

246 252 285

Depth of Pond 55mm 52mm

Dry Beach Length 17mm 35mm

Fluid Capacity 56 litre 54 litre

Liquid Capacity

Ring Dam Size

246 252 285

Depth of Pond 55mm 52mm 35mm

Dry Beach Length 17mm 35mm 130mm

Fluid Capacity 56 litre 54 litre 42 litre

Factors Affecting Performance & Unit
Selection
Application factors Feed Properties

Mode of Operation 
Mud density
 Unweighted 
Feed rate
 Weighted

Slurry properties
 Dual mode
 Viscosity
 1 unit dual purpose
 Density
 Polishing cuttings dryer
 Unique solids present
effluent
 Chemical Enhanced  Unusual temperature
Dewater (CED)
Solids Removal Mode

The application is limited to unweighted applications only

Select unit on G-force as first criteria
 The most common G-force operating range for
unweighted is 1500 to 2000 G’s
 A minimum of 1000 G’s is recommended for this
application. Depending of the many conditions, the unit
could run as high as high 3000 G’s

The goal: Maintain the minimum target mud weight
Solids removal mode: Unweighted application

Process at
75 –80% capacity.
Solids removal mode: Operational tips


G Force
 Minimum 1000 Gs
 Nominal 1500 – 2000 Gs

Do not run higher G force than the application requires

Volume criteria: Select longer bowl models for greater volume. Speed range can
typically be achieved to generate the desired G force.

It’s recommended to run the units at 75% -80% capacities to avoid pushing torque
limits

When adding dilution water to the active system, make the additions at the
centrifuge feed pipe.
 Dilution of the feed stream effectively reduces viscosity, which will enhance
centrifuge efficiency.
Solids removal mode: Operational tips

 Avoiding running the units for prescribed hourly

intervals per day once solids are in check. This will
improve the opportunity for reliability for steady
continuous service.
 Running a lower GPM rate around the clock, as
opposed to 6 – 8 hours a tour at a higher feed rate.
This will also maintain more consistent mud
properties as well.
Weighted water base applications
Weighted water base applications
Barite recovery mode: Operational tips

Rule of Thumb
 In most cases only 600 Gs are required for
barite recovery.
 No more than 700 Gs should ever be
required.
 Adjust feed and pond settings to achieve a
9.5 ppg / 30-35 Funnel Viscosity on the
effluent discard.
Barite Recovery Mode:
Operational Tips
Rule of Thumb
 Run the unit with a purpose.
A. If your more concerned about cleaning up a the
overall system of fines; go for volume and sacrifice
cut point.
B. Once you have stabilized PV and want to maintain or
tweak the system; run continuously at a low volume.
C. If a PV problem persist, increase pond depth
 
Dual Stage Centrifuge
.
Dual Stage Centrifuge
Review of Centrifuge Operation

Begin with the proper unit selection for the application or
applications

Never assume the unit has been set up to proper speed
and G force.

Never assume or leave rig-up details to some one else

Be field-wise about discharge slide fabrication

Always use a positive displacement or variable speed
progressive cavity feed pump.

Operate the unit with a purpose in response to the mud
parameters, properties and well program goals.
Decanting Centrifuge Types


Various manufacturers / styles used

Options
 Fixed or variable speed drive
 Fixed or variable speed back drive
 Hydraulic or electric motors

Typically centrifuges are identified by the bowl size
 example; 14 in. diameter x 49 in. length